阅读说明：本技术 一种叠加绕线电阻及其制法 (Superposed winding resistor and manufacturing method thereof ) 是由 李尚祐 于 2021-03-19 设计创作，主要内容包括：本发明是有关一种叠加绕线电阻及其制法,该叠加绕线电阻包括：具有阻抗值的陶瓷棒,并在其上涂装基本绝缘层,其具有第一端及第二端；第一绕线电阻,具有第一金属绕线,其具有第一线头及第一线尾,为环绕式地自该陶瓷棒的第一端缠绕该陶瓷棒的第二端,其中该第一金属绕线涂装第一绝缘层于其上；以及至少一个第二绕线电阻,为垂直叠置于该第一绕线电阻及该具有阻抗值的陶瓷棒上,且该具有阻抗值的陶瓷棒、该第一绕线电阻与该至少一个第二绕线电阻组成预定的并联电路连接,以提升抗突波性。(The invention relates to a superimposed winding resistor and a manufacturing method thereof, wherein the superimposed winding resistor comprises the following components: a ceramic rod having a resistance value, and a base insulating layer coated thereon, having a first end and a second end; a first winding resistor having a first metal winding having a first wire end and a first wire end, and being wound around the second end of the ceramic rod from the first end thereof, wherein the first metal winding is coated with a first insulating layer thereon; and at least one second winding resistor vertically superposed on the first winding resistor and the ceramic rod with impedance value, the first winding resistor and the at least one second winding resistor form a preset parallel circuit connection to improve the anti-surge property.)

1. A stacked winding resistor, comprising:

a ceramic rod having a resistance value, and a base insulating layer coated thereon, having a first end and a second end;

a first metal winding having a first end and a first end, which is wound around the second end of the ceramic rod from the first end of the ceramic rod, wherein the first metal winding is coated with a first insulating layer thereon to form a first winding resistor;

a second metal winding with a second end and a second end wound on the first winding resistor from the first end of the ceramic rod in a surrounding manner, wherein the second metal winding is coated with a second insulating layer to form a second winding resistor,

therefore, the second winding resistor is vertically overlapped on the first winding resistor and the ceramic rod with the impedance value to form a multilayer overlapped winding resistor, and the first winding resistor and the second winding resistor form a preset circuit connection to improve the anti-surge property.

2. The laminated winding resistor as claimed in claim 1, further comprising a third winding resistor stacked on the second winding resistor to form a three-layer laminated winding resistor, which comprises a third metal winding having a third end and a third end, which is wound around the second winding resistor from the first end of the ceramic rod, wherein the third metal winding is coated with a third insulating layer to form a third winding resistor, and wherein the third winding resistor is vertically stacked on the second winding resistor, and the ceramic rod having the impedance value, the first winding resistor, the second winding resistor and the third winding resistor are connected in parallel.

3. The superposed winding resistor as claimed in claim 1, wherein the predetermined circuit connection is parallel connection or the first metal winding and the second metal winding are reversely wound to form a non-inductive resistor.

4. The laminated wire-wound resistor as claimed in claim 1, wherein the ceramic rod is a ceramic rod, or is formed by combining a ceramic rod with high heat dissipation property with a metal film, a metal oxide film, a carbon film or a glass glaze film.

5. The overlaid routing resistor of claim 1, further comprising a first cap and a second cap, which are respectively arranged at two ends of the ceramic rod and extend outwards from the first end and the second end, wherein the first and second wire ends and the first and second wire tails are electrically welded to the surfaces of the first and second caps respectively, wherein the first cap and the second cap are respectively electroplated with a first cap electroplated layer and a second cap electroplated layer, and wherein the basic insulating layer and the first insulating layer cannot be coated on the cap during coating, after the second metal wire is wound around from the first end to the second end of the ceramic rod with the impedance value, the electric welding points of the head and the tail of the first metal winding and the second metal winding are reinforced and electroplated together, and the cap is also coated when the second insulating layer is coated for packaging.

6. The laminated wire-wound resistor of claim 5, further comprising two externally connected metal leads extending axially outwardly from said first and second cap plating, respectively, for external electrical connection.

7. The overlaid routing resistor of claim 5, wherein the material of the first and second caps is iron, silver, nickel, copper or alloys thereof.

8. The overlaid wire-wound resistor of claim 2, wherein the material of the first, second and third insulating layers is epoxy resin, silicon-based non-flammable paint or enamel paint.

9. The laminated wire-wound resistor of claim 6, wherein the material of the externally connected metal leads is a copper alloy to improve thermal conductivity.

10. A method for manufacturing a superposed winding resistor comprises the following steps:

providing a ceramic rod with a resistance value, and coating a basic insulating layer on the ceramic rod, wherein the basic insulating layer is provided with a first end and a second end;

providing a first metal winding wire which is provided with a first wire head and a first wire tail and is used for winding the second end of the ceramic rod from the first end of the ceramic rod in a surrounding manner;

coating a first insulating layer on the first metal winding to form a first winding resistor;

providing a second metal winding wire which is provided with a second wire head and a second wire tail and is wound on the first winding wire resistor from the first end of the ceramic rod in a surrounding manner;

coating a second insulating layer on the second metal winding to form a second winding resistor,

therefore, the second winding resistor is vertically overlapped on the first winding resistor and the ceramic rod with the impedance value to form a multilayer overlapped winding resistor, and the first winding resistor and the second winding resistor form a preset circuit connection to improve the anti-surge property.

11. The method according to claim 10, further providing at least one third winding resistor to be superimposed on the second winding resistor.

12. The method for manufacturing a super wound varistor as claimed in claim 10, wherein said predetermined circuit connection is parallel connection or reverse winding of said first metal winding and said second metal winding to form said non-inductive varistor.

13. The method for manufacturing a stacked wire-wound resistor as claimed in claim 10, wherein the ceramic rod is a ceramic rod, or a ceramic rod with high heat dissipation property is combined with a metal film, a metal oxide film, a carbon film or a glass glaze film.

14. The method for manufacturing a stacked winding resistor as claimed in claim 10, further comprising providing a first cap and a second cap respectively disposed at both ends of the ceramic rod to extend outwardly from the first end and the second end, and electrically welding the first wire end and the second wire end and the first wire end and the second wire end to the surfaces of the first cap and the second cap, respectively, and further electroplating the first cap plated layer and the second cap plated layer, respectively, and wherein the base insulating layer and the first insulating layer cannot be coated to the caps during coating, and the second metal winding is circularly electroplated from the first end to the second end of the ceramic rod having the impedance value, and then the electrical welding points of the wire ends and the wire ends of the first metal winding and the second metal winding can be reinforced together, and during encapsulation by coating the second insulating layer, the cap is also coated.

15. The method for manufacturing a stacked winding resistor as claimed in claim 10, further comprising two metal leads extending axially outwardly from the first cap plating layer and the second cap plating layer, respectively, for external electrical connection.

16. The method of claim 10, wherein the first cap and the second cap are made of iron, silver, nickel, copper or alloys thereof.

17. The method for manufacturing a super wound resistor as claimed in claim 10, wherein the first, second and third insulating layers are made of epoxy resin, silicon-based non-flammable paint or enamel paint.

18. The method for manufacturing a stacked winding resistor as claimed in claim 10, wherein the material of the external metal leads is copper alloy to improve thermal conductivity.

Technical Field

The invention relates to a superposed winding resistor and a manufacturing method thereof, in particular to a vertical superposed winding resistor which can greatly improve the surge resistance and a manufacturing method thereof.

Background

In the electronic field, the winding resistor is mainly suitable for being used as a voltage dividing, voltage reducing, current dividing and load resistor in alternating current and direct current circuits of precision instruments, medical equipment, telecommunication instruments, electronic equipment and the like, and can also provide a surge resistance function so as to prevent a circuit from being damaged due to a surge generated by instantaneous high voltage. When the transient voltage is too high, the general winding resistor still cannot bear and is disconnected, so that the operation of the circuit is affected, wherein the ceramic rod of the winding resistor has no resistance value. In addition, Japanese patent No. 3208923 and U.S. Pat. No. 9,978,483 (the same inventor as the present invention) disclose surge-resistant winding resistors and their manufacturing methods, which are mainly designed to electroplate cap-plated layers on both end caps, respectively, which can improve some surge-resistant capability.

In addition, in some specific applications of electronic equipment (e.g., a Defibrillator), it is desirable to have a simple winding resistor for protecting and safely operating the circuit.

Therefore, it is desirable to obtain a winding resistor that can effectively resist surge voltage to maintain the safe and normal operation of electronic equipment.

Disclosure of Invention

The main object of the present invention is to provide a stacked winding resistor and a method for manufacturing the same, which can have higher (at least several times) surge resistance than the common winding resistor when the instantaneous voltage reaches more than several kv, so as to maintain the safe and normal operation of the electronic circuit or equipment.

It is still another object of the present invention to provide a stacked winding resistor with a simple structure to maintain the safe and proper operation of the electronic device in a specific application requiring multiple transient high voltages.

The invention relates to a superposed winding resistor, which comprises: a ceramic rod having a resistance value, and a base insulating layer coated thereon, having a first end and a second end; a first metal winding having a first end and a first end, which is wound around the second end of the ceramic rod from the first end of the ceramic rod, wherein the first metal winding is coated with a first insulating layer thereon to form a first winding resistor; the second metal winding wire is wound on the first winding resistor from the first end of the ceramic rod in a surrounding mode, wherein the second metal winding wire is coated with a second insulating layer to form a second winding resistor, therefore, the second winding resistor is vertically overlapped on the first winding resistor and the ceramic rod with the impedance value, and the first winding resistor, the ceramic rod with the impedance value and the second winding resistor form preset circuit connection so as to improve the anti-surge property.

In addition, a method for manufacturing a stacked winding resistor according to the present invention includes: providing a ceramic rod with a resistance value, and coating a basic insulating layer on the ceramic rod, wherein the basic insulating layer is provided with a first end and a second end; providing a first metal winding wire which is provided with a first wire head and a first wire tail and is used for winding the second end of the ceramic rod from the first end of the ceramic rod in a surrounding manner; coating a first insulating layer on the first metal winding to form a first winding resistor; providing a second metal winding wire which is provided with a second wire head and a second wire tail and is wound on the first winding wire resistor from the first end of the ceramic rod in a surrounding manner; and coating a second insulating layer on the second metal winding to form a second winding resistor, wherein the second winding resistor is vertically overlapped on the first winding resistor and the ceramic rod with the impedance value, and the first winding resistor and the second winding resistor form a preset circuit connection to improve the anti-surge property.

Drawings

FIG. 1 is a diagram of a stacked winding resistor, which is a structure of two layers of vertically stacked resistors, according to an embodiment of the invention.

FIG. 2 is a diagram of a stacked winding resistor, which is a structure of a three-layer vertically stacked resistor, according to another embodiment of the present invention.

FIG. 3 shows a non-inductive overlay winding resistor with reverse winding of the metal winding according to another embodiment of the present invention.

The first table shows a comparative table of 5kv test reports for a Defibrillator (Defibrillator) (test for comparison of the present invention and general wire resistance).

Detailed Description

As shown in fig. 1, a double-layer stacked winding resistor 100 according to an embodiment of the present invention includes: a ceramic rod 110 having a resistance value completely different from a conventional ceramic rod having no resistance value of a wire-wound resistor, and coated with a base insulating layer 111 having a first end 112 and a second end 113; a first metal winding 121 having a first end 122 and a first end 123, for winding the first end 112 of the ceramic rod 110 around the second end 113 of the ceramic rod, wherein the first metal winding 121 is coated with a first insulating layer 124 thereon to form a first winding resistor 120; a second metal winding 131 having a second wire end 132 and a second wire end 133, which is wound around the first winding resistor 120 from the first end of the ceramic rod, wherein the second metal winding is coated with a second insulating layer 134 to form a second winding resistor 130, and thus the second winding resistor 130 is vertically stacked on the first winding resistor 120 and the ceramic rod 110 with the impedance value to form a multi-layer stacked winding resistor, and the first winding resistor and the second winding resistor form a predetermined parallel circuit connection to improve the anti-surge property.

In the double-layer superposed winding resistor of the invention, the predetermined circuit connection is parallel connection or the first metal winding and the second metal winding are reversely wound to form a non-inductive resistor.

The ceramic rod is a solid ceramic resistor rod, or a ceramic rod having high heat dissipation and a thermal conductivity of 10W/mk or more, in combination with a metal film, a metal oxide film, a carbon film, or a glass glaze film.

Also, in the overlay winding resistor of the present invention, it further comprises a first cap 151 and a second cap 152 respectively disposed at both ends of the ceramic rod to extend outward from the first end and the second end, wherein the first wire end and the second wire end and the first wire end and the second wire end are respectively electrically welded to the surfaces of the first cap and the second cap, and wherein the first cap and the second cap are respectively plated with a first cap plating layer (not shown in the drawing) and a second cap plating layer (not shown in the drawing). The basic insulating layer 111 and the first insulating layer 124 cannot be coated on the cap during coating, and after the second metal wire is wound around from the first end to the second end of the ceramic rod with the impedance value, the electrical pads of the wire ends and the wire tails of the first metal wire and the second metal wire can be reinforced and electroplated together, and the first cap 151 and the second cap 152 are also coated during coating the second insulating layer 134 for encapsulation.

In short, as shown in fig. 1, in the two-layer wiring resistor structure, the first cap 151 and the second cap 152 are also coated on the outermost second insulating layer; as shown in fig. 3, the coating of the third insulating layer is performed by coating the first cap 151 and the second cap 152. In the multilayer laminated wire-wound resistor of the present invention, the insulation coated on the uppermost layer of the wire-wound resistor is also coated on the caps at both ends.

In addition, two external metal leads 161, 162 are included, which extend axially outward from the first and second cap plating layers, respectively, for external electrical connection.

As for the material, the material of the first cap and the second cap is iron, silver, nickel, copper or the alloy thereof. The first, second and third insulating layers are made of epoxy resin, silicon-based non-combustible paint or enamel paint.

In addition, the material of the externally-connected metal lead is copper alloy so as to improve the heat conductivity.

With this structure, the stacked winding resistor of the present invention can further stack at least one third winding resistor (detailed in fig. 2 below) on the double-layered stacked winding resistor, such as a third layer winding resistor, a fourth layer winding resistor, etc., depending on the resistance value and the surge-resistant voltage.

The stacked winding resistor further includes at least one third winding resistor, such as a third winding resistor and/or a fourth winding resistor stacked on the second winding resistor. FIG. 2 shows a structure of the third winding resistor.

As shown in fig. 2, a three-layer vertically stacked wire resistor 100' according to another embodiment of the present invention further includes a third metal wire 141 having a third terminal 142 and a third terminal 143, which is wound around the second wire resistor 130 from the first end 112 of the ceramic rod, wherein the third metal wire 141 is coated with a third insulating layer 143 thereon to form a third wire resistor 140, and wherein the third wire resistor is vertically stacked on the second wire resistor 130, and the first wire resistor 120, the second wire resistor 130 and the third wire resistor 140 are connected in parallel.

As shown in fig. 3, according to the overlay winding resistor 100 of another embodiment of the present invention, the first metal winding 121 of the first winding resistor 120 and the second metal winding 131 of the second winding resistor 130 are reversely wound, so that the overlay winding resistor forms a non-inductive resistor.

The invention provides a method for manufacturing a superposed winding resistor, which comprises the following steps:

providing a ceramic rod with a resistance value, and coating a basic insulating layer on the ceramic rod, wherein the basic insulating layer is provided with a first end and a second end;

providing a first metal winding wire which is provided with a first wire head and a first wire tail and is used for winding the second end of the ceramic rod from the first end of the ceramic rod in a surrounding manner;

coating a first insulating layer on the first metal winding to form a first winding resistor;

providing a second metal winding wire which is provided with a second wire head and a second wire tail and is wound on the first winding wire resistor from the first end of the ceramic rod in a surrounding manner;

and coating a second insulating layer on the second metal winding to form a second winding resistor, wherein the second winding resistor is vertically stacked on the first winding resistor and the ceramic rod with the impedance value to form a multilayer stacked winding resistor, and the ceramic rod with the impedance value and the second winding resistor form a preset circuit connection to improve the anti-surge property of the first winding resistor.

The superposed winding resistor further comprises at least one third winding resistor superposed on the second winding resistor. As shown in fig. 2 in detail, as shown in fig. 3, the metal windings of the first winding resistor and the second winding resistor of the present invention can be reversely wound to make the superposed winding resistor a non-inductive resistor.

The ceramic rod is made of a solid ceramic resistor rod, or a ceramic rod with high heat dissipation and a thermal conductivity of 10W/mk, which is combined with a metal film, a metal oxide film, a carbon film or a glass glaze film.

In addition, in the method for manufacturing the superposed winding resistor, a first cap and a second cap can be further provided, which are respectively arranged at two ends of the ceramic rod and extend outwards from the first end and the second end, and the first wire end and the second wire end as well as the first wire tail and the second wire tail are respectively electrically welded on the surfaces of the first cap and the second cap, so that a first cap electroplated layer and a second cap electroplated layer are respectively electroplated on the first cap and the second cap. The basic insulating layer and the first insulating layer can not be coated on the cap when coating, after the second metal winding is wound from the first end to the second end of the ceramic rod with the impedance value in a surrounding manner, the electric welding points of the head and the tail of the first metal winding and the second metal winding can be reinforced and electroplated together, and the cap can be coated when the second insulating layer is coated again for packaging.

In addition, two metal leads may be further connected to the first cap plating layer and the second cap plating layer, respectively, extending outwards from the axial direction of the first cap and the second cap for external electrical connection, wherein the first cap and the second cap are made of iron, silver, nickel, copper or alloys thereof.

In addition, the first insulating layer, the second insulating layer and the third insulating layer are made of epoxy resin, silicon-based non-combustible paint or enamel paint.

Furthermore, the material of the external metal lead is copper alloy to improve the thermal conductivity.

The defibrillator 5kv pulse test shown in the attached table one is in accordance with the test standard AANSI/AAMI EC53:2013IEC 60601-2-27:2011, which is the electrocardiogram ECG medical standard (https:// webstore. ie. ch/publication/2638). As shown in the attached table, the test conditions were: the pulse voltage is 5 kv; number of pulse is 10 times;

test samples: (1) nos.1,2 and 3: SSWA 03 of the present invention (surge-resistant winding resistance 4k Ω connected in parallel with 2.7k Ω then 2.7k Ω, note: three-layer stacked winding resistance)

(2) General winding resistors Nos.4,5,6 (0.9920 k omega, 0.9854k omega, 0.9888k omega respectively)

After the test: normally, the winding resistor 3 is seriously damaged by explosion open circuit at the first pulse.

The invention comprises the following steps: the resistance values of the high-resistance resistor are 1.0204k omega, 1.0128k omega and 1.0277k omega respectively, the resistance values are normal, the change rate of the resistance values is within 10%, and the anti-surge capacity is improved by more than 10 times. A

[ TABLE ] A

Description of the reference numerals

Superposed winding resistor of 100, 100'

Ceramic rod 110 having a resistance value

Basic insulating layer 111

First end 112

Second end 113

First winding resistor 120

The first metal wire 121

First thread end 122

First wire tail 123

First insulating layer 124

Second winding resistor 130

Second metal wire 131

Second thread end 132

Second wire tail 133

Second insulating layer 134

First cap 151

Second cap 152

Metal leads 161, 162

Third winding resistor 140

Third metal wire 141

Third thread end 142

Third wire tail 143

Third insulating layer 144